System for processing and producing an aggregate

ABSTRACT

An aggregate processing assembly is provided. The processing assembly includes a separator assembly having a central member extending from a first end to a second end, the central member supporting at least one helical flight provided between the first and second ends, the helical flight having a width provided between a proximal end and a distal end. An assembly housing is provided around a portion of the separator assembly, the assembly housing includes a collection portion for receiving processed feed stock which exits the separator assembly radially away from the central member outward past the distal end, and the collection portion includes a first outlet. A second outlet is coupled to the separator assembly for receiving processed feed stock which exits the separator assembly at the second end of the at least one helical flight. A proppant, an aggregate, a system for processing feed stock to produce a proppant or aggregate, and a method of producing a proppant or aggregate is also provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/665,987, filed Jun. 29, 2012, entitled SEPARATOR, to U.S. ProvisionalApplication No. 61/675,794, filed Jul. 25, 2012, entitled SPIRALSEPARATOR, and to U.S. Provisional Application No. 61/691,173, filedAug. 20, 2012, entitled SPIRAL OR HELICAL SEPARATOR DEVICE, SYSTEM AND ANOVEL METHOD FOR SORTING OR PURIFYING A FRAC SAND OR A PROPPANT, thecontents of which are hereby incorporated by reference in theirentirety.

FIELD OF THE INVENTION

The present invention relates to aggregate particles. More specifically,the present invention relates to a novel process and system for theprocessing and production of aggregate particles. The resultingaggregate particles may include proppants usable in the oil or gasindustry to prop open subterranean fractures around oil and gas wells,or in a gravel-packing operation, such as for sand control.

BACKGROUND

Aggregates and proppants are generally known in the art. An aggregate isa component of a composite material which provides certain properties tothe composite material, including bulk and/or resistance to compressivestress. A proppant, which is a type of an aggregate, is a material usedto hold open or “prop” an area in which the proppant is introduced. Inthe oil or gas industry, a proppant is typically used in associationwith hydraulic fracturing operations, and in sand control, such as ingravel-pack operations.

During the hydraulic fracturing process, a conductive fracture isinduced underground in order to provide a path of extraction for atargeted subterranean material, such as a hydrocarbon, including oil orgas. Typically, a fracturing fluid is introduced into the targetedsubterranean area. The fracturing fluid creates hydraulic fracturesunderground to the targeted subterranean materials. The hydraulicfractures provide a path for the targeted subterranean materials to beextracted, for example through an underground well. In order to keep theinduced hydraulic fractures open, to maintain the fracture width, and/orto slow the decline of the fractures, a proppant is typically introducedinto the hydraulic fractures. The proppant slows and/or inhibits closureof the fractures when the fracturing fluid is reduced. Accordingly, anappropriate proppant has the ability to flow into the fractures, theability to form a “pack” or a partial monolayer that provides supportand maintains the fractures in an open state, the ability to withstandsubstantial crushing force in the subterranean area (i.e. crushresistance), and the ability to facilitate flow of a hydrocarbon to anextraction bore or to a well head.

The volume and rate of hydrocarbon production through subterraneanfractures or a wellbore can be a function of proppant conductivity.Proppant conductivity is the product of proppant permeability andfracture width. Hydrocarbon production rate can also be influenced byfracture length and the contact area of fractures with reservoirhydrocarbons. For example, an increase in proppant conductivity,fracture length, or fracture contact area with reservoir hydrocarbonscan increase the hydrocarbon productivity of a well. Similarly, adecrease in proppant conductivity, fracture length, or fracture contactarea with reservoir hydrocarbons can decrease the hydrocarbonproductivity of a well.

Due to the necessary requirements of a proppant in hydraulic fracturing,only certain materials are suitable for use as a proppant. For example,some naturally occurring sands, known as “frac sand,” meet theserequirements. Other materials used as a proppant include, but are notlimited to, glass beads, steel shot, nut shells, ceramic pellets,synthetic resin pellets, sintered alumina or bauxite, a polymer, shells,or a mixture of any of these materials.

When designing or selecting a proppant, several proppant propertiestypically are taken into consideration, as the properties can affectproppant performance to achieve proppant conductivity, fracture length,and ultimately hydrocarbon production. As some of these properties canconflict with each other, the benefit and the cost typically needs to beconsidered prior to the design or selection of the proppant for atargeted application. In addition, the targeted application can varydepending upon certain factors of a well, including, but not limited to,formation type, formation depth, the treatment to be applied, and/or theequipment to be used.

For example, compressive forces in a fracture can often exceed 1,000pounds per square inch or psi. A significant fraction of particulatesmaking up a proppant can withstand these compressive forces withoutcrushing or substantially breaking. A frac sand or a lightweight ceramicis often used in applications where compressive forces are less thanabout 10,000 psi, such as for relatively shallow wells. In deeper wells,where compressive forces can exceed 15,000 psi, higher strengthproppants are typically used. These higher strength proppants are oftencomposed of materials having a relatively higher specific gravity thanother proppants, such as ceramic or bauxite.

The crushing of a proppant has certain disadvantages, including areduction in fracture width or close and “pinch off” of a fracture,reducing proppant conductivity. In addition, fines generated from acrushed proppant can clog a proppant pack void space, reducing proppantpack permeability, and thus reducing proppant conductivity. Further,sharp-edged fines may be generated from a crushed proppant. Thesesharp-edged fines can concentrate the compression force onto an adjacentparticle sphere, leading to the crushing of the adjacent particle andsubsequent release of additional sharp-edged fines.

While a proppant having a higher specific gravity can improve crushresistance, transportability of the proppant is often compromised,requiring higher viscosity pumping fluids and/or higher pumping rates.In addition, proppants having a higher density generally have highermaterial costs. This is in addition to additional costs for largerpumping equipment and increased wear rates of fluid carrying equipment.

As another example, the size range of particles making up a proppant istypically relatively narrow and historically controlled throughfractionation using sieves. The size range of particles is typicallymeasured in terms of the diameter of the particles. An example of sizerange distributions of a proppant include, but are not limited to, 6/12,8/16, 12/18, 12/20, 16/20, 16/30, 20/40, 30/50, 40/60, 40/70, 70/140,and 100 Mesh as according to U.S. sieve pan sizes used to fractionatethe proppant. Narrower size range distributions of a proppant arecommercially produced, for example for a ceramic proppant. For example,these narrower size range distributions may include 18/20, 20/30, and30/40. Generally, a narrower size range distribution of a proppantmaintained under stress can improve conductivity through increasedproppant permeability. However, Median Particle Diameter (MPD) of aproppant can also significantly affect conductivity, as generally thelarger the MPD, particularly when maintained under stress or pressure,the greater the conductivity.

A proppant having particles of a smaller MPD can exhibit a higher crushstrength and a longer transport distance due to a reduced settling rate.Both of these factors can promote fracture productivity. However, anincrease in fracture length and a corresponding increase inaccessibility to reservoir hydrocarbons must be weighed againstpotentially reduced permeability and associated reduced conductivity ofthe proppant pack formed by these particles. A reduction in permeabilityand conductivity can reduce fracture productivity.

On the other hand, a proppant having particles of a larger MPD,particularly when maintained under stress, can exhibit relatively highpermeability and high conductivity, promoting fracture productivity.However, these particles can settle relatively faster, compromisingfracture length and potentially reducing accessibility to hydrocarbonsand fracture productivity. Further, these particles can have a reducedcrush resistance. Thus, upon crushing can reduce MPD, fracture width,reducing proppant permeability and conductivity.

As another example, the shape of particles in a proppant can profoundlyimpact its conductivity. Historically, proppants have been sought thathave a spherical and rounded shape to maximize load bearing capacity andto even stress distribution, and maximize corresponding crushresistance, permeability, flowability, delivery distance within afracture, effective fracture width through reduced embedment, andreduced pressure loss, tortuosity, friction against hydrocarbon flow,and abrasion. Together, these shape-dependent properties can serve toincrease the effective conductivity of a proppant, and ultimatelyincrease hydrocarbon production rates.

Packing together spheroidal or largely spherical and rounded particlescan form capillary-like flow channels through a proppant matrix, leadingto reduced tortuosity, and associated reduced pressure loss. This is ofparticular importance in areas of high flow rates, such as near a wellbore or areas of fracture convergence. In these areas, fractures andfluid flow converge and Non-Darcy flow effects can be most pronounced.While spheroidal particles of uniform size offer excellent conductivity,these particles can be prone to flow-back into the well bore. Flow-backof a proppant is undesirable as it can reduce the volume of proppant inthe fractures, reducing the productivity through the fractures. Further,proppant flowing back into the well bore and to the surface can abradewell bore components and surface equipment, leading to expensiveequipment repair, equipments replacement, and costly downtime.Additional costs can be incurred for the removal and disposal offlow-back proppant from the oil and gas produced from the well bore.

As another example, the surface texture of particles in a proppant canimpact proppant performance. A smooth surface texture can offer certainadvantages, such as a reduced coefficient of friction. A reducedcoefficient of friction can reduce flow friction, resulting in anincrease in flow capacity of a fluid through a fracture. Conversely,irregularities on the outside surface of a proppant can lead to unevenstress distribution, proppant crushing, and fine generation. Further,surface irregularities can trap fracturing fluid used during injection,closing up a void space in a proppant pack and reducing proppantpermeability and conductivity. This in turn reduces oil or natural gasproduction. Additionally, a prolonged clean-up of injection fluid can beexpensive and cause delays in oil or natural gas production.

Surface irregularities, for example in the form of dents, protrusions,burs, rough surface textures, or angular edges has the additionaldisadvantage of a high degree of abrasiveness. The presence of anabrasive particle in the well bore during injection or production candamage well and pumping equipment, increasing tool and equipment costsand leading to costly well downtime. However, surface irregularitiespotentially can reduce proppant flow-back.

In addition, the presence of clusters in a proppant can have adverseaffects on the proppant. A cluster is formed of many small granularparticles, and has a rough surface texture. Clusters can reduce thestrength of the proppant, increase flow friction, and ultimately reduceproppant conductivity. Clusters are often found in frac sand.

The presence of contaminant particles in a proppant can also haveadverse affects on the proppant. Contaminant particles are often foundin frac sand, and may include feldspar, mica, magnetite, hematite,biotite, milky quartz, iron ore, and/or dolomite. Contaminant particlescan reduce proppant strength, increase acid solubility, increaseabrasiveness, increase flow friction, and ultimately reduce proppantconductivity.

As another example, additional requirements for a proppant can includechemical inertness towards fracturing fluid crosslinkers and breakers,and acid tolerance.

Progress has been made to optimize functionality of certain syntheticproppants, such as ceramic proppants. For example, a lightweight ceramicproppant can have a relatively low specific gravity, and a high degreeof sphericity and roundness. However, production costs of syntheticproppants can be high and further increased when the particle sizedistribution is narrowed. In addition, synthetic proppants can be highlyabrasive and can incur additional costs related to equipment damage,tooling damage, and well downtime when used.

Frac sand, while relatively inexpensive, typically includes aheterogeneous mixture of particle shapes, which include irregularlyshaped particles and highly spherical and rounded particles. Further,frac sand typically includes a heterogeneous mixture of particle surfacetextures, and may also include clusters and/or contaminants. Where someparticles of frac sand have a smooth surface texture, other particleshave a rough surface texture. Irregular or angular shaped frac sandparticles, or particles having a rough surface texture can have adetrimental impact on conductivity, and ultimately can reduce the rateof hydrocarbon production. In addition, the abrasiveness of these fracsand particles incurs additional costs related to equipment damage,tooling damage, and well downtime when used.

Similar to frac sand, resin-coated frac sand or resin-coated sandincludes a relatively heterogeneous mixture of particle shapes,including irregularly shaped particles and highly spherical and roundedparticles. While a resin coating can slightly improve sphericity orroundness of a frac sand particle, significant irregularities in shapewithin the particle population remain. Resin-coated sand can be usednear the well bore, a zone of high fluid velocity and turbulence, inorder to reduce proppant flow-back into the well. A resin-coating canalso reduce fine generations, and maintain a high structural integrityof proppant by improved crush resistance. This together acts to optimizeconductivity and hydrocarbon flow through the well bore. However, resinchipping can lead to clogged void space, reduced permeability, andreduced strength of the resin-coated sand. In addition, resin-coatedsand requires a costly special treatment which can be negativelyaffected by temperature.

Currently, no processing system exists that through direct modificationcan increase sphericity and roundness of frac sand to produce agenerally highly spherical and rounded frac sand without alsointroducing surface irregularities or pre-stress particles of the fracsand. For example, while a sand reclamation system can be used to rubtogether frac sand particles in order to increase the sphericity androundness of the particles, in doing so, dents and/or protractions canresult on the surface of the particles. In another example of a system,a frac sand particle is repeatedly shot at high velocity against a metalplate to achieve a spherical and rounded particle shape. However, thisprocess can lead to pre-stressing or fracturing of the particle,reducing crush resistance of the particle. In addition, in both systemexamples, significant waste is incurred during shape modification to thefrac sand particles.

In addition, no processing system exists that can remove abrasiveparticles from a frac sand to produce an abrasion-resistant frac sand.An attrition scrubber can be used to remove a surface irregularity froma frac sand particle, reducing the roughness of surface texture andassociated abrasiveness of the frac sand particle. However, an attritionscrubber is unable to significantly remove or affect relatively moreangular, un-spherical, or irregularly shaped particles or clusters, orparticles having a rough surface texture. These abrasive particlesremain in the frac sand processed by an attrition scrubber.

Due to the disadvantages of irregularly shaped, rough surface texturesand, there is a need for a sand that is of highly spherical and roundedshape, is smooth of surface texture, yet retains the benefits of a lowspecific gravity. Further, a sand size gradation or MPD is currently notnecessarily optimized for one or more proppant properties. There is aneed for the ability to further modify a sand size gradation or MPD toresult in optimal performance or economics of a proppant. In addition,there is a need for a more abrasion-resistant proppant that is lessabrasive than a typical frac sand or a synthetic proppant, such as aceramic proppant.

Furthermore, there is a need for a sand that exhibits greaterpermeability and conductivity, particularly for use near or adjacent tothe well bore. This sand can be resin-coated, such as to further reduceflow-back, reduce fine generation, or to increase the strength of thesand. Furthermore, there is a need for a sand that would be analternative to resin-coated sand, as the sand would not requireresin-coating of particles, but that similarly reduces proppantflow-back.

In addition, due to the limited number of naturally-occurring aggregateparticle deposits for certain uses, there is a need for a system ofprocessing aggregate particles to acquire particles having certaindesired properties. For example, there are a limited number ofnaturally-occurring aggregate particle deposits, such as sand, suitablefor use as a proppant. As another example, there are a limited number ofnaturally-occurring aggregate particle deposits, such as sand, suitablefor use in other industries, including, but not limited to, sandblasting, molding, shot peening, concrete, masonry, landscaping,agriculture, artificial turf, electronics, or filtration.

In addition, shipping of an aggregate particle can be expensive, and caneconomically limit access to certain aggregate particles. Morespecifically, while an aggregate particle of a distant deposit may haveone or more beneficial properties, it can be cost prohibitive to shipcompared to a local deposit. Accordingly, there is a need for a systemof processing aggregate particles which may be movable.

SUMMARY OF THE DESCRIPTION

The present invention provides an improved system for processing andproducing a hydraulic fracturing proppant or a proppant for use in sandcontrol methods, such as in a gravel-pack. The present inventionprovides a system for processing relatively inexpensive materials, suchas sand and/or silica sand, to produce a proppant having the desired andsuitable properties to serve as an effective hydraulic fracturingproppant. In addition, the present invention provides a system which canbe mobile. Further, the present invention provides for the production ofa value added proppant suitable to serve as an effective hydraulicfracturing proppant or for use in sand control.

A proppant is provided. The proppant results from a separator means andcomprises a plurality of particles. The particles have an averageKrumbein and Sloss Sphericity Value of 0.6 or above, and an averageKrumbein and Sloss Roundness Value of 0.6 or above.

A proppant resulting from a separator means which separates a feed stockis also provided. The proppant comprises a plurality of particles, theparticles have an average Krumbein and Sloss Sphericity Value of atleast 0.01 greater than the average Krumbein and Sloss Sphericity Valueof the feed stock. The proppant includes a plurality of particles, theparticles have an average Krumbein and Sloss Roundness Value of at least0.01 greater than the average Krumbein and Sloss Sphericity Value of thefeed stock. In addition, a proppant is provided that can include alarger or smaller MPD or a modified size distribution profile comparedto the feedstock through use of the separator means or screeningapparatus.

An aggregate resulting from a processing means which separates a feedstock is also provided. The aggregate includes a plurality of particles,the particles have an average median particle diameter of at least 1micron more than the average median particle diameter of the feed stock.

A proppant processing assembly is also provided. The processing assemblyincludes a separator assembly having a central member extending from afirst end to a second end, the central member supporting at least onehelical flight provided between the first and second ends, the helicalflight having a width provided between a proximal end and a distal end.An assembly housing is provided around a portion of the separatorassembly, the assembly housing includes a collection portion forreceiving processed feed stock which exits the separator assemblyradially away from the central member outward past the distal end, andthe collection portion includes a first outlet. A second outlet iscoupled to the separator assembly for receiving a second fraction ofprocessed feed stock which exits the separator assembly at the secondend of the at least one helical flight.

A recombinant aggregate is also provided. The recombinant aggregateincludes a first aggregate fraction resulting from a processing means,the first aggregate having a first particle size profile, a secondaggregate fraction resulting from a processing means, the secondaggregate having a second particle size profile, wherein the first andsecond aggregate fractions are combined at a ratio such that theresulting mixture has a third particle size profile different from thefirst particle size profile and second particle size profile.

A recombinant aggregate is also provided. The recombinant aggregateincludes a first aggregate fraction resulting from a processing means,the first aggregate having a first particle shape profile, a secondaggregate fraction resulting from a processing means, the secondaggregate having a second particle shape profile, wherein the first andsecond aggregate fractions are combined at a ratio such that theresulting mixture has a third particle shape profile different from thefirst particle shape profile and second particle shape profile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of one or more examples of embodiments of aprocessing assembly for the production of a proppant.

FIG. 2 is front elevation view of the processing assembly of FIG. 1,illustrating the front side of the processing assembly and thecontainment shield in an open position.

FIG. 3 is a rear elevation view of the processing assembly of FIG. 1,illustrating the back side of the processing assembly and thecontainment shield in an open position.

FIG. 4 is an isometric view of a portion of the processing assembly ofFIG. 1, illustrating the separator assembly of the processing assemblyand the containment shield in an open position.

FIG. 5 is a close up view of a portion of the processing assembly ofFIG. 1, taken along line 5-5 of FIG. 4.

FIG. 6 is a close up view of a portion of the processing assembly ofFIG. 1, taken along line 6-6 of FIG. 4.

FIG. 7 is a close up view of a portion of the processing assembly ofFIG. 1, taken along line 7-7 of FIG. 4.

FIG. 8 is a close up view of a portion of the processing assembly ofFIG. 1, taken along line 8-8 of FIG. 7.

FIG. 9 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating a collectionportion.

FIG. 10 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating a rimprovided about a portion of a flight.

FIG. 11 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating a splitterprovided in line with a plurality of flights.

FIG. 12 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating one or moreslots provided in a first portion of a flight.

FIG. 13 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating one or moreslots provided in a second portion of a flight.

FIG. 14 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating one or moreslots provided in a third portion of a flight.

FIG. 15 is a close up view of one or more examples of embodiments of aportion of the processing assembly of FIG. 1, illustrating a collectionassembly for collecting processed feedstock removed by one or more slotsprovided in a flight.

FIG. 16 is an isometric view of one or more examples of embodiments of aprocessing system implementing at least one processing assembly of FIG.1.

FIG. 17 is an isometric view of the processing system of FIG. 16illustrating the access doors in an open position.

FIG. 18 is a side view of the processing system of FIG. 16 illustratingthe housing as removed.

FIG. 19 is an isometric view of the processing system of FIG. 18illustrating the housing as removed.

FIG. 20A is an isometric view of one or more examples of embodiments ofa processing system implementing a plurality of processing systems inparallel, each having at least one processing assembly of FIG. 1

FIG. 20B is an isometric view of one or more examples of embodiments ofa processing system implementing a plurality of processing systems inseries, each having at least one processing assembly of FIG. 1

FIG. 21 is a photomicrograph of one or more examples of particlesprovided in an exemplary feed stock, the feed stock having a 20/30 sizefraction, the photomicrograph being 37.5× magnification.

FIG. 22 is a photomicrograph of a captured processed fraction of highlyabrasive particles following processing of the feed stock of FIG. 21,the photomicrograph being 37.5× magnification.

FIG. 23 is a photomicrograph of a captured processed fraction ofabrasive particles following processing of the feed stock of FIG. 21,the photomicrograph being 37.5× magnification.

FIG. 24 is a photomicrograph of a captured processed fraction ofabrasion-resistant particles following processing of the feed stock ofFIG. 21, the photomicrograph being 37.5× magnification.

FIG. 25 is a photomicrograph of a captured processed fraction ofabrasion-resistant particles following processing of the feed stock ofFIG. 21, the photomicrograph being 37.5× magnification.

FIG. 26 is a photomicrograph of a captured processed fraction of highlyabrasion-resistant particles following processing of the feed stock ofFIG. 21, the photomicrograph being 37.5× magnification.

FIG. 27 is a photomicrograph of one or more examples of particlesprovided in an exemplary feed stock, the feed stock having a 20/40 sizefraction, the photomicrograph being 37.5× magnification.

FIG. 28 is a photomicrograph of a captured processed fraction ofspherical particles following processing of the feed stock of FIG. 27,the photomicrograph being 37.5× magnification.

FIG. 29 is a photomicrograph of a captured processed fraction of superspherical particles following processing of the feed stock of FIG. 27,the photomicrograph being 37.5× magnification.

DETAILED DESCRIPTION

The invention illustrated in the Figures and disclosed herein isgenerally directed to a processing assembly 100 for the production of aproppant or an aggregate, a system of the production of a proppant or anaggregate, a method of producing a proppant or an aggregate, and anassociated proppant or aggregate. More specifically, the processingassembly, system, method, and associated proppant have certainproperties suitable for use as a proppant in hydraulic fracturing, sandcontrol, and/or gravel-pack operations. It should be appreciated thatthe feed stock may be unprocessed or processed, and may be a proppant oran aggregate. Further, the feed stock may be treated or coated, forexample resin coated. The feed stock may also be dry or relatively dryprior to processing. In addition, any of the processed fractions may besuitable as an aggregate or a proppant. In addition, any of theprocessed fractions may be suitable as an aggregate or a proppant alone,or in combination with one or more separate fractions or one or morefeed stocks. It should be appreciated that the Figures provided hereinare for illustration and are not necessarily to scale.

It should be appreciated that the disclosure provided herein mayreference roundness and/or sphericity. Roundness is the measure of thesharpness of a particle's edges and corners. The more rounded or lesssharp the edges and corners, the higher the particle roundness.Sphericity is the measure of how spherical a particle is, typically incomparison to a perfect sphere. The more spherical shape of theparticle, the higher the particle sphericity. Both roundness andsphericity may be respectfully graded on a scale from 0.0. to 1.0, with1.0 being either perfectly round or perfectly spherical. Roundnessand/or sphericity may be graded using the Krumbein and Sloss Table,which is a visual comparison chart for particle roundness and particlesphericity developed by William C. Krumbein and Laurence L. Sloss. TheKrumbein and Sloss Table describes particle roundness and particlesphericity for a range of particle shapes, using values ranging from 0.1to 0.9. A particle having a Krumbein and Sloss Roundness Value of 0.1 isless round, while a particle having a Krumbein and Sloss Roundness Valueof 0.9 is more round. Similarly, a particle having a Krumbein and SlossSphericity Value of 0.1 is less spherical, while a particle having aKrumbein and Sloss Sphericity Value of 0.9 is more spherical.Hereinafter, the Krumbein and Sloss Roundness or Krumbein and SlossSphericity values may respectively be referenced as a “K&S” Roundness or“K&S” Sphericity value.

Referring now to the Figures, FIGS. 1-3 illustrate one or more examplesof embodiments of a processing assembly 100 for the processing and/orproduction of an aggregate or a proppant. Assembly 100 may include a rawstock distribution assembly or feed stock delivery assembly 110. Feedstock delivery assembly 110 is in operable communication with aseparator assembly or feed stock sorting assembly or spiral separationassembly 120. Separator assembly 120 may be in operable communicationwith a first processed feed stock discharge, such as first outlet 130,and a second processed feed stock discharge, such as second outlet 132.In one or more examples of embodiments, separator assembly 120 mayinclude more than two outlets for the selective removal of processedfeedstock or fractions thereof.

Feed stock delivery assembly 110 may include a supply chest or headboxor stuffbox or feed stock supply chamber 112. Supply chest 112 may beprovided to maintain an amount of feed stock to processing assembly 100.Supply chest 112 may further act as a retention tank in order forprocessing assembly 100 to operate as a batch process. In thealternative, processing assembly 100 may operate as a continuousprocess. As a continuous process, feed stock may be provided to supplychest 112 through any suitable or desired assembly, for example a supplyline, pipe, tube, shaker, conveyor or other suitable supply assembly. Inone or more alternative examples of embodiments, processing assembly 100may continuously operate without a supply chest 112, instead having asuitable supply assembly providing feed stock to separator assembly 120.

A feed stock supply line 114 may be operably connected to supply chest112. Supply line 114 preferably transfers feed stock from supply chest112, to separator assembly 120. Supply line 114 may include a feed stockflow control (not illustrated). Flow control may be a valve forincreasing or decreasing feed stock flow through supply line 114 toseparator assembly 120. Flow control may be a manual hand valve or maybe an automated valve adapted to actuate by command, for example anelectronic command.

Referring now to FIGS. 1-2, separator assembly 120 may be in operablecommunication with feed stock supply line 114. More specifically, feedstock may pass from feed stock supply line 114 to separator assembly120. As illustrated in the figures, separator assembly 120 is a spiralor helical or helical-like separator for the processing of feed stock.Separator assembly 120 may include a plurality of flights 122 (as shownin FIG. 4). Each of the plurality of flights 122 may be provided about acentral member or core member 124. Generally, each of the plurality offlights 122 is provided in a helical or helical-like orientation aboutcore member 124. Each of the plurality of flights 122 may extend from anentry end or first end 125 of separator assembly 120 to an exit end orsecond end 126 of separator assembly 120. As illustrated, each of theplurality of flights 122 makes approximately four revolutions about coremember 124. It should be appreciated in one or more examples ofembodiments that each of the plurality of flights 122 may make fewerthan approximately four revolutions about core member 124, or may makemore than approximately four revolutions about core member 124. Itshould be appreciated in one or more examples of embodiments thatseparator assembly 120, one or more of the plurality of flights 122, ora portion thereof may be made of, formed of, composed of, coated with,and/or be treated with an abrasion resistant material.

FIGS. 5 and 6 provide a close up view of entry end 125 of separatorassembly 120. Entry end 125 may include central member 124. Theplurality of flights 122 helically extend from central member 124. Asillustrated in FIG. 7, the plurality of flights 122 are helically nestedor intertwined. The nested plurality of flights 122 provides additionalsurface area to process a larger volume of feed stock than a singlehelical flight. As shown, eight flights 122 a-122 h helically extendabout central member 124. The flights 122 a-h (shown in FIG. 8)originate from an entry end 125 of central member 124. It should beappreciated in one or more examples of embodiments of separator assembly120 that more than eight flights 122 or fewer than eight flights 122 mayhelically extend about central member 124.

As illustrated in FIG. 11, each of flights 122 has a proximal end 121and a distal end 123. Proximal end 121 of each flight 122 is providedclosest to central member 124, while distal end 123 is provided awayfrom central member 124 opposite proximal end 121. Each of flights 122may be at least perpendicular to central member 124. Preferably, each offlights 122 form an acute angle or angle of less than ninety degreeswhich extends between central member 124 and each connected flight 122.It should be appreciated in one or more examples of embodiments that oneor more flights 122, or one or more portions of flights 122 may have avariable angle between central member 124 and the flight 122 across theflight 122 from proximal end 121 to distal end 123. Stated otherwise,one or more flights 122, or one or more portions of flights 122 may beapproximately arcuate from proximal end 121 to distal end 123. Inaddition, the length of each flight 122 as measured from proximal end121 to distal end 123 may be between one inch and two hundred and fortyinches, more specifically may be between about two inches and twentyfour inches, and more specifically may be between about three inches andsix inches. However, in one or more examples of embodiments, the lengthof each flight 122 as measured from proximal end 121 to distal end 123may be any desired or targeted length based upon various factors,including, but not limited to, the type of unprocessed feed stock, theprocessing volume, the feed stock flow rate, the flight angle, thetargeted properties of the portion of the feed stock processed byseparator assembly 120, and/or the yield of the portion of the feedstock processed by separator assembly 120. Generally, each of flights122 is accessible or open at distal end 123. In one or more examples ofembodiments, a portion of each of flights 122 may be accessible or openat distal end 123 to allow for a certain portion of feed stock to exitthe associated flights 122.

Referring to FIG. 5, a funnel or entry shield 127 may be provided aroundcentral member 124. In addition funnel 127 may be provided around aportion of flights 122. Funnel 127 may assist in directing feed stockfrom supply line 114 into separator assembly 120 through entry end 125.

Referring to FIG. 5, supply line 114 may include a dispersal member ordisperser 118. In one or more examples of embodiments, dispersal member118 may be coupled to supply line 114 by one or more attachment members(not shown). Dispersal member 118 may be a conical member 118 adapted todisperse or spread out or distribute feed stock from supply line 114prior to entering separator assembly 120. It should be appreciated inone or more examples of embodiments that dispersal member 118 may be anyshape or size suitable to disperse or distribute feed stock from supplyline 114 prior to entering separator assembly 120.

Referring to FIG. 7, the plurality of flights 122 helically extend aboutcentral member 124 from entry end 125 to exit end 126. As illustrated inFIG. 8, a termination member 128 may be provided at the desiredtermination point of the plurality of flights 122. Termination member128 may extend from the distal end 123 of each of the plurality offlights 122 toward the proximal end 121 of each of the plurality offlights 122. Termination member 128 is adapted to direct a portion offeed stock to a second outlet 132. Second outlet 132 may be coupled to aportion of central member 124. For example, as illustrated, centralmember 124 is substantially hollow. Accordingly, termination member 128directs a portion of feed stock into one or more apertures (not shown)provided in central member 124 at the second end 126. Second outlet 132is accordingly coupled to central member 124 at the second end 126, suchthat a portion of feed stock directed by termination member 128 exitsseparator assembly 120 through second outlet 132. In one or moreexamples of embodiments, termination member 128 may be provided along aportion of the plurality of flights 122 to direction a portion ofprocessed feed stock to an outlet, such as the second outlet 132. Inaddition, termination member 128 may be movable radially between theproximal and distal ends 121, 123. Further, termination member 128 maybe extendable radially to provide different sizes of termination member128 between the proximal and distal ends 121, 123.

Referring back to FIGS. 1-3, separator assembly 120 may be provided inan assembly housing 140. Assembly housing 140 may be provided around theperimeter of separator assembly 120 and substantially encase separatorassembly 120. Assembly housing 140 may include an access panel 141 toallow access to separator assembly 120. As shown in FIGS. 1 and 2,access panel 141 may be pivotally connected to a portion of assemblyhousing 140 to enable selective access to separator assembly 120. Inaddition, a portion of access panel 141 may include one or moretransparent panels to enable observation of operation of separatorassembly 120.

Separator assembly 120 may be mounted on or supported by a supportmember 142. Support member 142 may be connected to or integrally formedwith assembly housing 140. Support member 142 may be any suitable memberable to structurally support separator assembly 120 during operation ofseparator assembly 120 in accordance with the present disclosure.

Assembly housing 140 may also include a collection portion 143. As shownin FIG. 8, collection portion 143 may be provided toward the exit end126 of separator assembly 120. Collection portion 143 may be a conicalor frustoconical portion which extends to a first outlet 130. Forexample, collection portion 143 may have a maximum inner diameter whichis equal to a maximum inner diameter of assembly housing 140. The innerdiameter of collection portion 143 subsequently will decrease fromassembly housing 140 toward first outlet 130. This is to facilitate orchannel a portion of processed feed stock through first outlet 130 andout of assembly 100. In one or more examples of embodiments, collectionportion 143 may be any suitable size or shape to facilitate collectionof a portion of the processed feed stock from separator assembly 120. Inaddition, in one or more examples of embodiments, collection portion 143may have a maximum inner diameter which is greater than a maximum innerdiameter of assembly housing 140.

Referring to FIGS. 1 and 2, assembly 100 may also include a plurality offrame members 144. Frame members 144 may be provided to support housing140 and the associated separator assembly 120. Frame members 144 may beof any suitable size, shape, and/or strength suitable to supportoperation of separator assembly 120 and/or to prevent settling orbuildup of particles atop frame member 144 in accordance with thedisclosure provided herein. In addition, a plurality of wheels 145 maybe coupled to frame members 144. Wheels 145 may allow assembly 100 to bemobile or moved to a desired location.

It should be appreciated in one or more examples of embodiments ofassembly 100, a plurality of separator assemblies 120 may be provided inan assembly housing 140. The plurality of separator assemblies 120 mayshare a common collection portion 143. In addition, the plurality ofseparator assemblies 120 may each have an outlet to a second outlet 132,or may each connect to a single, common second outlet 132.

In operation and use of assembly 100, a feed stock is introduced toassembly 100. For example, the feed stock may be naturally occurringsand, including, but not limited to silica sand. Further, the feed stockmay be a specific sand or a commonly found sand. The feed stock likelywill have a broad range of particle properties, including, but notlimited to, a relatively broad roundness and/or sphericity profile.Stated otherwise, the feed stock likely will have particles having arange of roundness and/or sphericity. For example, the feed stock mayhave an average Krumbein and Sloss Roundness Value of 0.1 to 0.9, morespecifically of 0.3 to 0.9, and more specifically of 0.5 to 0.9. Inaddition, the feed stock may have an average Krumbein and SlossSphericity Value of 0.1 to 0.9, more specifically of 0.3 to 0.9, andmore specifically of 0.5 to 0.9. Assembly 100 will process the feedstock to separate the substantially round and substantially sphericalfeed stock particles from the remaining feed stock particles, or removesubstantially angular or irregular particles. This process will resultin a portion of the feed stock being preferable for use as a proppant,and further as a proppant for use in hydraulic fracturing, or sandcontrol, such as a gravel packing operation.

It should be appreciated that prior to introduction to assembly 100,feed stock may be prescreened before introduction to the feed stockdelivery assembly 110. For example, in one or more examples ofembodiments, feed stock may be prescreened to capture a size fraction orgrade of the feed stock. A suitable size fraction or grade may be 20/40.However, it should be appreciated that a suitable size fraction or grademay include, but is not limited to, 6/12, 8/16, 12/18, 12/20, 16/20,20/40, 16/30, 30/50, 40/60, 40/70, 70/140, 100 mesh, and/or any othersuitable or desired size fraction or grade. The fraction or grade isgenerally determined by the maximum screen size through which apercentage of particles pass and the minimum screen size through which apercentage of the particles do not pass. Typically, the smaller thenumber, the larger the screen sieve opening size, while the larger thenumber, the smaller the screen sieve opening size. Consequently, thesize fraction or grade is generally defined by the maximum screen sizeand the minimum screen size. It should also be appreciated that one ormore fractions of feed stock processed by assembly 100 and/or separator120 may be screened based upon size to modify the size distributionprofile of one or more fractions.

Once introduced into the feed stock delivery assembly 110, theprescreened feed stock or feed stock may be metered or fed ortransferred to separator assembly 120. For example, the feed stock maytravel through supply line 114 to entry end 125 of separator assembly120. In addition, the feed stock may be dispersed or spread out bycontacting dispersal member 118 after exiting supply line 114 andentering separator assembly 120 at entry end 125. Dispersal member 118may distribute the feed stock across entry end 125 of separator assembly120.

The feed stock will be distributed upon one of the plurality of flights122. The feed stock will then travel along each associated flight 122,moving helically around central member 124. As the feed stock travelsalong each associated flight 122, feed stock which is of a greaterroundness and/or a greater sphericity will generally travel towards thedistal end 123 of each associated flight 122. Feed stock which is oflower roundness and/or a lower sphericity will generally remain on eachassociated flight 122. For example, feed stock which is of lowerroundness and/or a lower sphericity may generally remain closer inproximity to the proximal end 121 than the distal end 123 of eachassociated flight 122.

As the feed stock continues to helically travel along each associatedflight 122, the portion of the feed stock having a greater roundnessand/or a greater sphericity will generally eventually exit the pluralityof flights 122 radially. Stated otherwise, the portion of the feed stockhaving a greater roundness and/or a greater sphericity will generallytravel beyond distal end 123 and exit separator assembly 120. Theportion of the feed stock having a lower roundness and/or a lowersphericity and which generally does not exit the plurality of flights122 radially will remain in contact with each associated flight 122until reaching termination member 128.

The portion of the feed stock generally having a greater roundnessand/or a greater sphericity and which radially exits separator assembly120 is collected in a collection portion, such as collection portion143. Housing 140 may assist in collection of the fraction which radiallyexits separator assembly 120. In addition, housing 140 may assist indirecting the fraction which radially exits separator assembly 120toward collection portion 143 and/or towards an outlet, such as firstoutlet 130. The portion of the feed stock generally having a greaterroundness and/or a greater sphericity subsequently leaves collectionportion 143 through first outlet 130. The exiting processed feed stockfrom first outlet 130 may then be further collected, stored, furtherprocessed, used as an aggregate, and/or used as a proppant.

The portion of the feed stock having a lower roundness and/or a lowersphericity and which generally remains in separator assembly 120 willreach termination member 128 and subsequently be directed from separatorassembly 120 to second outlet 132. For example, the portion of the feedstock having a lower roundness and/or a lower sphericity will generallybe directed into at least one aperture provided in central member 124 bytermination member 128. The portion of the feed stock having a lowerroundness and/or a lower sphericity will then travel to second outlet132, exiting assembly 100. The exiting processed feed stock from secondoutlet 132 may then be further collected, stored, further processed,and/or discarded.

It should be appreciated in one or more examples of embodiments ofassembly 100, that the desired property for the processed feed stockwhich exits assembly 100 radially may be adjusted, targeted, and/oroptimized. While the above steps of operation and use of assembly 100references processing of a feed stock by sphericity and/or roundness,assembly 100 may process a feed stock based upon one or more otherdesired properties of the feed stock.

For example, in one or more examples of embodiments, the feed stock maybe processed according to particle size. In such an example, as the feedstock travels along each associated flight 122, moving helically aroundcentral member 124, the feed stock which is of a greater size or agreater diameter will generally travel towards the distal end 123 ofeach associated flight 122. Feed stock which is of a smaller size orsmaller diameter will generally remain on each associated flight 122.For example, feed stock which is of a smaller size or smaller diametermay generally remain closer in proximity to the proximal end 121 thanthe distal end 123 of each associated flight 122.

As the feed stock continues to helically travel along each associatedflight 122, the portion of the feed stock having a greater size orgreater diameter will generally eventually exit the plurality of flights122 radially. Stated otherwise, the portion of the feed stock having agreater size or greater diameter will generally travel beyond distal end123 and exit separator assembly 120. The portion of the feed stockhaving a smaller size or smaller diameter and which does not exit theplurality of flights 122 radially will generally remain in contact witheach associated flight 122 until reaching termination member 128.

The portion of the feed stock having a greater size or greater diameterand which radially exits separator assembly 120 is collected in acollection portion, such as collection portion 143. The portion of thefeed stock having a greater size or greater diameter subsequently leavescollection portion 143 through first outlet 130. The exiting processedfeed stock from first outlet 130 may then be further collected, stored,further processed, used as an aggregate, and/or used as a proppant.

The portion of the feed stock having a smaller size or smaller diameterand which generally remains in separator assembly 120 will reachtermination member 128 and subsequently be directed from separatorassembly 120 to second outlet 132. For example, the portion of the feedstock having a smaller size or smaller diameter will generally bedirected into at least one aperture provided in central member 124 bytermination member 128. The portion of the feed stock having a smallersize or smaller diameter will generally then travel to second outlet132, exiting assembly 100. The exiting processed feed stock from secondoutlet 132 may then be further collected, stored, further processed,and/or discarded.

As another example, in one or more examples of embodiments, the feedstock may be processed according to particle surface texture. In such anexample, as the feed stock travels along each associated flight 122,moving helically around central member 124, the feed stock which has asurface texture which is smoother or less rough will generally traveltowards the distal end 123 of each associated flight 122. Feed stockwhich has a surface texture which is less smooth or more rough willgenerally remain on each associated flight 122. For example, feed stockwhich has a surface texture which is less smooth or more rough maygenerally remain closer in proximity to the proximal end 121 than thedistal end 123 of each associated flight 122.

As the feed stock continues to helically travel along each associatedflight 122, the portion of the feed stock which has a surface texturewhich is smoother or less rough will generally eventually exit theplurality of flights 122 radially. Stated otherwise, the portion of thefeed stock which has a surface texture which is smoother or less roughwill generally travel beyond distal end 123 and exit separator assembly120. The portion of the feed stock which has a surface texture which isless smooth or more rough and which does not exit the plurality offlights 122 radially will generally remain in contact with eachassociated flight 122 until reaching termination member 128.

The portion of the feed stock which has a surface texture which issmoother or less rough and which radially exits separator assembly 120is collected in a collection portion, such as collection portion 143.The portion of the feed stock which has a surface texture which issmoother or less rough subsequently leaves collection portion 143through first outlet 130. The exiting processed feed stock from firstoutlet 130 may then be further collected, stored, further processed,used as an aggregate, and/or used as a proppant.

The portion of the feed stock which has a surface texture which is lesssmooth or more rough and which generally remains in separator assembly120 will reach termination member 128 and subsequently be directed fromseparator assembly 120 to second outlet 132. For example, the portion ofthe feed stock which has a surface texture which is less smooth or morerough will be directed into at least one aperture provided in centralmember 124 by termination member 128. The portion of the feed stockwhich has a surface texture which is less smooth or more rough will thentravel to second outlet 132, exiting assembly 100. The exiting feedstock from second outlet 132 may then be further collected, stored,further processed, and/or discarded.

While the above examples of embodiments of assembly 100 referenceprocessing feed stock according to one or more desired or targeted feedstock properties, including, particle shape, particle size, and/orparticle surface texture, the exemplary list of properties is notexhaustive. For example, the feed stock may be processed by assembly 100targeting specific gravity of the feed stock, rollability of theparticles and/or feed stock (i.e. how well the feed stock rolls or therolling velocity of the feed stock), and/or an interaction of theparticles and/or feed stock with the assembly material or components.

In addition, in one or more examples of embodiments, one or moreassemblies 100 may be provided in series, or stacked, or otherwiseoperated as stages. In these embodiments, each stage of the assembly 100will further purify, beneficiate, fractionate, sort, or concentrate thefeed stock based upon the desired or targeted feed stock property. Forexample, a first stage of one or more assemblies 100 may process feedstock in accordance with a desired or targeted property, includingparticle shape, particle size, particle surface texture, particlespecific gravity, particle rollability, and/or particle interaction withthe assembly material. The processed feed stock which exits the one ormore assemblies 100 of the first stage through a processed feed stockdischarge, for example the first outlet 130 and/or second outlet 132,may subsequently be further processed in a second stage of one or moreassemblies 100. The second stage may further process the feed stockbased upon the same desired or targeted property as the first stage, ormay process the feed stock based upon a different desired or targetedproperty as the first stage. In addition, any number of stages may beprovided with the processed feed stock which exits the one or moreassemblies 100 of the previous stage through a processed feed stockdischarge, for example the first outlet 130 and/or second outlet 132,being further processed by the next stage.

One or more additional acquisition assemblies 410, 420, 430, 440 may beincorporated into assembly 100, and more specifically separator assembly120, to acquire, fractionate, retain, or separate or remove or produceone or more desired fractions of processed feed stock.

FIG. 9 illustrates one or more examples of embodiments of a secondcollection portion or collection assembly 410. Collection portion 410includes a first collection member 412 coupled to a second collectionmember 414. Preferably, first collection member 412 may be coupled tocentral member 124. In addition, first collection member 412 may beprovided approximately parallel or angled relative to the plurality offlights 122 of separator 120. First collection member 412 may behelically or helically-like provided about central member 124 for aportion of the helical or helical-like revolutions of flights 122. Firstcollection member 412 generally has a radius or width extending awayfrom central member 124 which is greater than the width or radius offlights 122. In addition, first collection member 412 may be provided onthe exit end 126 of the plurality of flights. Around the perimeter offirst collection member 412 opposite central member 124 may be thesecond collection member 414. As illustrated, second collection member414 may be provided at an angle to first collection member 412. Inaddition, second collection member 414 may be provided at an angle toflights 122. Second collection member 414 is preferably provided adistance radially away from flights 122, and more specifically adistance radially away from the distal end 123 of flights 122.Collection portion 410 assists in collecting processed feed stock whichradially leaves separator 120.

FIG. 10 illustrates one or more examples of embodiments of a portion ofa flight 122 having a rim or radial rim 420. Rim 420 is preferablyprovided on distal end 123 and extends perpendicular or angled relativeto flight 122. Rim 420 is provided to restrict loaded or processedfeedstock from exiting radially outward from flight 122, past the distalend 123. This forces the feed stock to be additionally processed by theflight 122 incorporated into assembly 100, and more specificallyseparator 120.

FIG. 11 illustrates one or more examples of embodiments of a portion ofa plurality of flights 122 having a splitter assembly 430. Splitterassembly 430 may include a splitter member 432 which bisects a portionof the flights 122 between the proximal end 121 and distal end 123.Splitter member 432 may also contact the surface of flights 122. Thesplitter member 432 may be coupled to a receiving chamber 434 having afirst receiving portion 436 and a second receiving portion 438. Thesplitter member 432 will separate the processed feedstock helicallytraveling along flights 122. The splitter member 432 will separate theprocessed feedstock into one of the first receiving portion 436 orsecond receiving portion 438, generating at least two fractions ofprocessed feedstock. It should be appreciated that in one or moreexamples of embodiments, splitter member 432 may be provided at anydesired or targeted location between proximal end 121 and distal end123. In addition, in one or more examples of embodiments, splittermember 432 may be adjustable to any desired or targeted location betweenproximal end 121 and distal end 123. Further, in one or more examples ofembodiments, splitter member 432 may not be in contact with the surfaceof one or more flights 122. In one or more examples of embodiments, aplurality of splitter members 432 may be provided between proximal end121 and distal end 123. The plurality of splitter member 432 mayseparate the processed feedstock into a plurality of fractions,directing the feedstock into a plurality of receiving portions. In oneor more examples of embodiments, one or more receiving portions may bein communication with one or more first ends 125 of one or moreadditional processing assemblies 100 and/or separator assemblies 120.Further, splitter member 432 may separate the processed feedstock intoone or more fractions and direct the one or more fractions to one ormore first ends 125 of one or more additional processing assemblies 100and/or separator assemblies 120. In addition, in one or more examples ofembodiments, a splitter member 432 may be provided to fewer than all ofthe plurality of flights 122.

FIGS. 12-15 illustrate one or more examples of embodiments of a slot orradial slot 440 provided in a flight 122. As illustrated, slot 440 maybe provided at a desired position radially extending across flight 122.Referring to FIG. 12, slot 440 may be provided at a position radiallyextending from near proximal end 121 toward distal end 123. Referring toFIG. 13, slot 440 may be provided at a position between proximal anddistal ends 121, 123 and radially extending across flight 122. Referringto FIG. 14, slot 440 may be provided at a position radially extendingfrom a position on flight 122 near distal end 123. Slot 440 may beprovided at any desired or targeted location across one or more flights122 to collect a desired or targeted portion or fraction of theprocessed feedstock. In addition, slot 440 may be any suitable ordesired radial length to collect a portion of a fraction of theprocessed feedstock. In addition, slot 440 may be any suitable ordesired width, which is perpendicular to the radial length, to collect aportion of a fraction of the processed feedstock. Referring to FIG. 15,a collection assembly 446 may be in communication with slot 440. Forexample, collection assembly 446 may be provided on the underside ofslot 440, and further on the underside of flight 122. Collectionassembly 446 may collect the portion of a fraction of the processedfeedstock which falls into slot 440 and remove that collected processedfeedstock from assembly 100. For example, collection assembly 446 maytransport the collected processed feedstock toward the proximal end 121of the flights, such as to the hollow central member 124. As anotherexample, collection assembly 446 may transport the collected processedfeedstock toward the distal end 123 of the flights, such as radiallyoutward to a separate collection assembly, collection bin, or collectioncolumn (not shown).

Referring to FIGS. 16-19, one or more examples of embodiments of aprocessing system 300 for processing feed stock is provided. Processingsystem 300 may include a plurality of processing assemblies 100 orcertain elements thereof. Referring to FIGS. 16 and 17, processingsystem 300 may include a modular housing 310 which surrounds theplurality of processing assemblies 100. Housing 310 may include aplurality of access hatches or doors 320. The access doors 320 may allowone or more users to access the interior of housing 310 where theplurality of processing assemblies 100 are housed. In addition, housing310 may be provided on or integrated with parallel inclined conveyors330 a, 330 b to allow for removal of at least two fractions of processedfeed stock from processing system 300.

FIGS. 18 and 19 illustrate processing system 300 with the housing 310removed. The processing system 300 includes a plurality of processingassemblies 100. In addition, the processing system 300 includes aplurality of separator assemblies 120. In addition a plurality ofconveyors 350, 360 may be provided. Conveyors 350 may convey a firstfraction of processed feed stock, for example feed stock which escapeseach of the separator assemblies 120 radially. For example, conveyors350 convey the first fraction of processed feed stock to conveyor 330 b.Conveyor 360 may convey a second fraction of processed feed stock, forexample feed stock which does not escape each separator assembly 120radially. For example, conveyor 360 conveys the second fraction ofprocessed feed stock to conveyor 330 a. In addition, a plurality ofcurtains or planes or enclosures 365 may be provided between one or moreseparators 120. Curtains 365 may assist in directing the first fractionof processed feed stock toward conveyor 350. In addition, curtains 365may assist in preventing particles of the first fraction from radiallyescaping one separator assembly 120 and entering an adjacent separatorassembly 120. Curtains 365 may be provided in a first planeperpendicular to conveyor 350, or in a second plane parallel to conveyor350. In addition, a diverter 370 may be provided for assisting indiverting the first fraction of processed feed stock to conveyor 350. Aplurality of extraction tubes 380 may be provided for transporting thesecond fraction of processed feed stock from each separator assembly 120to conveyor 360. In one or more examples of embodiments, extractiontubes 380 may be in communication with separator assembly 120. Inaddition, extraction tubes 380 may pass through respective aperturesprovided in diverter 370 to allow the second fraction to travel toconveyor 360.

In one or more examples of embodiments of system 300, system 300 mayinclude a prescreening assembly (not shown) to prescreen raw feed stock.For example, the prescreening assembly may be any suitable screeningapparatus to screen, disperse, or vibrate feed stock prior tointroduction to separator assembly 120. Such a suitable prescreeningapparatus may screen feed stock to a suitable size fraction, for examplea 20/40 fraction. However, it should be appreciated that a suitable ordesired prescreening may be implemented, for example, but not limited toprescreening feed stock to a size fraction of 6/12, 8/16, 12/18, 12/20,16/20, 20/40, 16/30, 30/50, 40/60, 40/70, 70/140, 100 mesh, and/or anyother suitable or desired size fraction. It should also be appreciatedthat one or more fractions of feed stock processed by assembly 100and/or separator 120 may be screened or post-screened based upon size tomodify the size distribution profile, mean particle size or diameter, ormedian particle size or diameter of one or more fractions.

FIGS. 20A and 20B illustrate one or more examples of embodiments of asystem 300 employing a plurality of modular housings 310. As illustratedin FIG. 20A, the plurality of modular housings 310 operates in parallelto process feedstock into at least two fractions. As illustrated in FIG.20B, a plurality of modular housings 310 may be arranged to operate inseries, with one or more modular housings 310 operating as a pluralityof processing stages. The plurality of modular housings 310 may bearranged to operate in series, and/or may be provided in an elevated orstacked arrangement in order to gravity feed stock from stage to stage.In addition, in one or more examples of embodiments, a plurality ofmodular housings 310 may be provided for each processing stage.

The resulting processed feed stock from assembly 100 produce differentaggregate grades for different applications or uses. The feed stock maybe processed by assembly 100 and/or separator 120 one or more times inorder for particles having one or more targeted or desired properties orcharacteristics to be separated as one or more fractions from theprocessed feed stock. As an example, one or more examples of anaggregate classification, and more specifically one or moreclassifications of sand processed by assembly 100 and/or separator 120,having certain targeted properties is illustrated in the followingtable:

Average Particle Average Particle Sphericity Roundness Classification(K&S) (K&S) Additional Properties Frac Sand ≧0.6 ≧0.6 Abrasive Sand ≧15%of the particles have a roundness ≦0.7; ≦15% of the particles have aroundness ≧0.9; and ≦15% of the particles have a sphericity ≧0.9 HighlyAbrasive ≧50% of the particles have a Sand roundness ≦0.7; ≧20% of theparticles have a roundness ≦0.6; <25% of the particles have a roundness≧0.8; <25% of the particles have a sphericity ≧0.8; and Includes theadditional properties of the Abrasive Sand classification Abrasion-≧0.79 ≧0.79 <15% of the particles have a Resistant Sand roundness≦0.7; >15% of the particles have a roundness ≧0.9; and >15% of theparticles have a sphericity ≧0.9 Highly Abrasion- ≧0.80 ≧0.80 <10% ofthe particles have a Resistant Sand roundness ≦0.7; >80% of theparticles have a roundness ≧0.8; >80% of the particles have a sphericity≧0.8; and Includes the additional properties of the Abrasion-ResistantSand classification Spherical Sand ≧0.85 ≧0.85 <10% of the particleshave a roundness ≦0.7; >85% of the particles have a roundness ≧0.8; >85%of the particles have a sphericity ≧0.8; and Includes the additionalproperties of the Highly Abrasion Resistant Sand Super Spherical ≧0.88≧0.88 <5% of the particles have a Sand roundness ≦0.7; >90% of theparticles have a roundness ≧0.8; >90% of the particles have a sphericity≧0.8; and Includes the additional properties of the Spherical Sandclassification

It should be appreciated that a distribution may be a component of aprofile. For example, a particle size distribution may be a component ofa particle size profile, a particle roundness distribution may be acomponent of a particle roundness profile, and/or a particle sphericitydistribution may be a component of a particle sphericity profile.

The following Examples provide an illustration of one or more examplesof embodiments of carrying out the invention disclosed herein. Morespecifically, the following Examples provide an illustration of one ormore fractions of a feed stock processed by assembly 100 and/orseparator 120. The following Examples are provided for illustration andare not intended to limit the scope of the invention.

A sample feed stock of sand having a 20/30 grade or size fraction isillustrated in FIG. 21. The feed stock was provided as a feed stock toseparator 120. The feed stock has an average K&S Sphericity Value of0.75 and an average K&S Roundness Value of 0.82. In addition, the feedstock has a roundness profile of 70% of the particles ≦0.8, 15% of theparticles ≦0.7, and 0% of the particles ≦0.6. In addition, the feedstock has a sphericity and roundness profile of 15% of the particleshaving a sphericity and roundness ≧0.9 and 55% of the particles having asphericity and roundness ≧0.8. The sphericity and roundness profile isthe percentage of particles having both a sphericity and a roundnesswithin the identified value range.

Example 1

The feed stock illustrated in FIG. 21 was processed by assembly 100, andmore specifically separator 120. The feed stock was processed on aseparator 120 having a six inch flight radius. In addition, splitterassembly 430 was provided along flights 122. The splitter assembly 430was provided one inch radially away from central member 124. Theresulting processed feed stock fraction between proximal end 121 orcentral member 124 and splitter assembly 430, and which was acquiredwithin the one inch radial distance, was captured. The capturedprocessed fraction is highly abrasive and is illustrated in FIG. 22. Thecaptured processed fraction has an average K&S Sphericity Value of 0.68and an average K&S Roundness Value of 0.73. In addition, the capturedprocessed fraction has a roundness profile of 80% of the particles ≦0.8,60% of the particles ≦0.7, and 20% of the particles ≦0.6. In addition,the captured processed fraction has a sphericity and roundness profileof 5% of the particles having a sphericity and roundness ≧0.9 and 15% ofthe particles having a sphericity and roundness ≧0.8.

Example 2

The feed stock illustrated in FIG. 21 was processed by assembly 100, andmore specifically separator 120. The feed stock was processed on aseparator 120 having a six inch flight radius. In addition, splitterassembly 430 was provided along flights 122. The splitter assembly 430was provided three inches radially away from central member 124. Theresulting processed feed stock fraction between proximal end 121 orcentral member 124 and splitter assembly 430, and which was acquiredwithin the three inch radial distance, was captured. The capturedprocessed fraction is abrasive and is illustrated in FIG. 23. Thecaptured processed fraction has an average K&S Sphericity Value of 0.76and an average K&S Roundness Value of 0.77. In addition, the capturedprocessed fraction has a roundness profile of 65% of the particles ≦0.8,45% of the particles ≦0.7, and 10% of the particles ≦0.6. In addition,the captured processed fraction has a sphericity and roundness profileof 5% of the particles having a sphericity and roundness ≧0.9 and 40% ofthe particles having a sphericity and roundness ≧0.8.

Example 3

The feed stock illustrated in FIG. 21 was processed by assembly 100, andmore specifically separator 120. The feed stock was processed on aseparator 120 having a six inch flight radius. In addition, splitterassembly 430 was provided along flights 122. The splitter assembly 430was provided three inches radially away from proximal end 121 or centralmember 124. The resulting processed feed stock fraction between splitterassembly 430 and distal end 123, and which was acquired within the threeinch radial distance between splitter assembly 430 and distal end 123(but which excluded particles escaping radially from separator 120) wascaptured. The captured processed fraction is abrasion-resistant and isillustrated in FIG. 24. The captured processed fraction has an averageK&S Sphericity Value of 0.83 and an average K&S Roundness Value of 0.86.In addition, the captured processed fraction has a roundness profile of35% of the particles ≦0.8, 10% of the particles ≦0.7, and 0% of theparticles ≦0.6. In addition, the captured processed fraction has asphericity and roundness profile of 30% of the particles having asphericity and roundness ≧0.9 and 80% of the particles having asphericity and roundness ≧0.8.

Example 4

The feed stock illustrated in FIG. 21 was processed by assembly 100, andmore specifically separator 120. The feed stock was processed on aseparator 120 having a six inch flight radius. In addition, splitterassembly 430 was provided along flights 122. The splitter assembly 430was provided three inches radially away from proximal end 121 or centralmember 124. The resulting processed feed stock fraction between splitterassembly 430 and distal end 123, and which was acquired within the threeinch radial distance, was captured. The captured processed fraction wasthen mixed with a second fraction of captured processed feed stock.Specifically, the second fraction was the fraction which exited theflights radially past the distal end 123 during processing throughseparator 120. The mixture of processed fractions is abrasion-resistantand is illustrated in FIG. 25. The mixture of processed fractions has anaverage K&S Sphericity Value of 0.79 and an average K&S Roundness Valueof 0.82. In addition, the captured processed fraction has a roundnessprofile of 70% of the particles ≦0.8, 10% of the particles ≦0.7, and 5%of the particles ≦0.6. In addition, the captured processed fraction hasa sphericity and roundness profile of 25% of the particles having asphericity and roundness ≧0.9 and 65% of the particles having asphericity and roundness ≧0.8.

Example 5

The feed stock illustrated in FIG. 21 was processed by assembly 100, andmore specifically separator 120. The feed stock was processed on aseparator 120 having a six inch flight radius. In addition, splitterassembly 430 was provided along flights 122. The splitter assembly 430was provided four inches radially away from proximal end 121 or centralmember 124. The resulting processed feed stock fraction between splitterassembly 430 and distal end 123, and which was acquired within the twoinch radial distance, was captured. The captured processed fraction wasthen mixed with a second fraction of captured processed feed stock.Specifically, the second fraction was the fraction which exited theflights radially past the distal end 123 during processing throughseparator 120. The mixture of processed fractions is highlyabrasion-resistant and is illustrated in FIG. 26. The mixture ofprocessed fractions has an average K&S Sphericity Value of 0.83 and anaverage K&S Roundness Value of 0.85. In addition, the mixture ofprocessed fractions has a roundness profile of 50% of the particles≦0.8, 5% of the particles ≦0.7, and 0% of the particles ≦0.6. Inaddition, the mixture of processed fractions has a sphericity androundness profile of 25% of the particles having a sphericity androundness ≧0.9 and 85% of the particles having a sphericity androundness ≧0.8.

As an additional set of examples, a second sample feed stock of sandhaving a 20/40 grade or size fraction is illustrated in FIG. 27. Thefeed stock was provided as a feed stock to separator 120. The feed stockhas an average K&S Sphericity Value of 0.78 and an average K&S RoundnessValue of 0.78. In addition, the feed stock has a roundness profile of60% of the particles ≦0.8, 25% of the particles ≦0.7, and 15% of theparticles ≦0.6. In addition, the feed stock has a sphericity androundness profile of 15% of the particles having a sphericity androundness ≧0.9 and 60% of the particles having a sphericity androundness ≧0.8.

Example 6

The second feed stock illustrated in FIG. 27 was processed by assembly100, and more specifically separator 120. The feed stock was processedon a separator 120 having a five inch flight radius. The resultingprocessed feed stock fraction which exited the flights radially past thedistal end 123 during processing through separator 120 was captured. Thecaptured processed fraction is spherical and is illustrated in FIG. 28.The captured processed fraction has an average K&S Sphericity Value of0.88 and an average K&S Roundness Value of 0.86. In addition, thecaptured processed fraction has a roundness profile of 30% of theparticles ≦0.8, 5% of the particles ≦0.7, and 0% of the particles ≦0.6.In addition, the captured processed fraction has a sphericity androundness profile of 50% of the particles having a sphericity androundness ≧0.9 and 95% of the particles having a sphericity androundness ≧0.8.

Example 7

The second feed stock illustrated in FIG. 27 was processed by assembly100, and more specifically separator 120. The feed stock was processedon a separator 120 having a five and a half (5.5) inch flight radius.The resulting processed feed stock fraction which exited the flightsradially past the distal end 123 during processing through separator 120was captured. The captured processed fraction is super spherical and isillustrated in FIG. 29. The captured processed fraction has an averageK&S Sphericity Value of 0.88 and an average K&S Roundness Value of 0.88.In addition, the captured processed fraction has a roundness profile of20% of the particles ≦0.8, 0% of the particles ≦0.7, and 0% of theparticles ≦0.6. In addition, the captured processed fraction has asphericity and roundness profile of 65% of the particles having asphericity and roundness ≧0.9 and 95% of the particles having asphericity and roundness ≧0.8.

As an additional set of examples, a third sample feed stock of sandhaving a 20/40 grade or size fraction was also provided as a feed stockto separator 120. The feed stock has a particle size, as measured by a20 pan having an 850 micron sieve opening size, and a 30 pan having a600 micron sieve opening size. The particle size distribution, as apercent of total weight retained in each pan, was 1.3% for the 20 pan,43.1% for the 30 pan, and 55.6% for the >30 pan. Similarly, the feedstock was measured by size using a U.S. Mesh Size of 20 to 30 (having aparticle size interval of between 850 to 600 microns), and 30 to 40(having a particle size interval of between 600 to 425 microns). Theparticle size distribution, as a percent of mass, was 43.1% for the 20to 30 mesh size, and 55.6% for the 30 to 40 mesh size. The mean particlediameter for the feed stock was 605 microns, and the median particlediameter was 580 microns. The feed stock was then processed by separator120 based upon particle size.

Example 8

The third feed stock was processed by assembly 100, and morespecifically separator 120 by particle size. The feed stock wasprocessed on a separator 120 having a five inch flight radius. Theresulting processed feed stock fraction which exited the flightsradially past the distal end 123 during processing through separator 120was captured. The captured processed fraction has a particle sizedistribution, as a percent of total weight retained in each pan, of 4.8%for the 20 pan, 84.1% for the 30 pan, and 11.1% for the >30 pan.Similarly, the captured processed fraction was measured by size using aU.S. Mesh Size. The particle size distribution, as a percent of mass,was 84.1% for the 20 to 30 mesh size, and 11.1% for the 30 to 40 meshsize. The mean particle diameter for the captured processed fraction was700 microns, and the median particle diameter was 720 microns.

Example 9

The third feed stock was processed by assembly 100, and morespecifically separator 120 by particle size. The feed stock wasprocessed on a separator 120 having a five inch flight radius. Theresulting processed feed stock fraction which remained on the flights atthe completion of the radial processing was captured. The capturedprocessed fraction has a particle size distribution, as a percent oftotal weight retained in each pan, of 0.9% for the 20 pan, 46.7% for the30 pan, and 52.4% for the >30 pan. Similarly, the captured processedfraction was measured by size using a U.S. Mesh Size. The particle sizedistribution, as a percent of mass, was 46.7% for the 20 to 30 meshsize, and 52.4% for the 30 to 40 mesh size. The mean particle diameterfor the captured processed fraction was 613 microns, and the medianparticle diameter was 590 microns.

Returning to the overall invention disclosed and provided herein, theinvention processes naturally occurring feed stock, for example, but notlimited to, sand or silica sand or silica containing sand orquartz-based silica sand, for use as a aggregate or proppant, andfurther as a proppant in the hydraulic fracturing process. The resultingproppant from the invention disclosed and provided herein may have thephysical properties set forth by API/ISO, including ISO 13503-2.

In addition, the resulting aggregate or proppant of a fractionpreferably has an increase in roundness and/or sphericity of at least0.01 over the feed stock, and more preferably an increase in roundnessand/or sphericity of at least 0.025 over the feedstock, and morepreferably an increase in roundness and/or sphericity of at least 0.05over the feed stock, and more preferably an increase in roundness and/orsphericity of at least 0.10 over the feed stock, and more preferably anincrease in roundness and/or sphericity of at least 0.15 over the feedstock.

In addition, the resulting aggregate or proppant of a fractionpreferably has a decrease in roundness and/or sphericity of at least0.01 over the feed stock, and more preferably a decrease in roundnessand/or sphericity of at least 0.025 over the feedstock, and morepreferably a decrease in roundness and/or sphericity of at least 0.05over the feed stock, and more preferably a decrease in roundness and/orsphericity of at least 0.10 over the feed stock, and more preferably adecrease in roundness and/or sphericity of at least 0.15 over the feedstock.

Further, the resulting aggregate or proppant preferably has an averageKrumbein and Sloss Sphericity Value of 0.6 to 1.0, more specifically anaverage Krumbein and Sloss Sphericity Value of 0.7 to 1.0, morespecifically an average Krumbein and Sloss Sphericity Value of more thanor equal to 0.8, and more specifically an average Krumbein and SlossSphericity Value of no less than or equal to 0.85, and more specificallyan average Krumbein and Sloss Sphericity Value of no less than or equalto 0.9.

In addition, the resulting aggregate or proppant preferably has anaverage Krumbein and Sloss Roundness Value of 0.6 to 1.0, morespecifically an average Krumbein and Sloss Roundness Value of 0.7 to1.0, more specifically an average Krumbein and Sloss Roundness Value ofmore than or equal to 0.8, and more specifically an average Krumbein andSloss Roundness Value of no less than or equal to 0.85, and morespecifically an average Krumbein and Sloss Roundness Value of no lessthan or equal to 0.9.

In addition, the resulting aggregate or proppant of a fraction may havepreferably an average Krumbein and Sloss Roundness Value of less than orequal to 0.8, more specifically an average Krumbein and Sloss RoundnessValue of less than or equal to 0.7, more specifically an averageKrumbein and Sloss Roundness Value of less than or equal to 0.65, andmore specifically an average Krumbein and Sloss Roundness Value of lessthan or equal to 0.6, and more specifically an average Krumbein andSloss Roundness Value of 0.5 to 0.6.

In addition, the resulting aggregate or proppant of a fraction may havepreferably an average Krumbein and Sloss Sphericity Value of less thanor equal to 0.8, more specifically an average Krumbein and SlossSphericity Value of less than or equal to 0.7, more specifically anaverage Krumbein and Sloss Sphericity Value of less than or equal to0.65, and more specifically an average Krumbein and Sloss SphericityValue of less than or equal to 0.6, and more specifically an averageKrumbein and Sloss Sphericity Value of 0.5 to 0.6.

In addition, the resulting aggregate or proppant preferably may have aturbidity of less than 250 NTU, a specific gravity of approximately 2 to3, more preferably below 2.8, and more preferably below 2.70, a crushresistance range of 1 to 25 K-value, and/or a solubility in 12/3 HCL/HFfor 0.5 hours at 150 degrees Fahrenheit of less than or equal to twopercent weight loss.

Further, the resulting aggregate or proppant having an increase ordecrease in average roundness and average sphericity over the feed stockpreferably has a yield of 0.1% to 99.9% by weight of the feed stock, andmore preferably has a yield of 1% to 99.5% by weight of the feed stock,and more preferably has a yield of 5% to 99% by weight of the feedstock, and more preferably has a yield of 10% to 99% by weight of thefeed stock, and more preferably has a yield of 15% and 99% by weight ofthe feed stock, and more preferably has a yield of 20% and 99% by weightof the feed stock.

Further, the resulting aggregate or proppant having an increase ordecrease in average roundness and average sphericity over the feed stockpreferably has a yield of 0.1% to 1% by weight of the feed stock, andmore preferably has a yield of 0.1% to 5% by weight of the feed stock,and more preferably has a yield of 0.1% to 10% by weight of the feedstock, and more preferably has a yield of 0.1% to 15% by weight of thefeed stock, and more preferably has a yield of 0.1% and 20% by weight ofthe feed stock, and more preferably has a yield of 0.1% and 50% byweight of the feed stock.

Further, the resulting aggregate or proppant may have an increase inaverage median particle diameter of 1 micron or more over the averagemedian particle diameter of the feed stock, more preferably have anincrease in average median particle diameter of 5 microns or more overthe average median particle diameter of the feed stock, more preferablyhave an increase in average median particle diameter of 10 microns ormore over the average median particle diameter of the feed stock, morepreferably have an increase in average median particle diameter of 20microns or more over the average median particle diameter of the feedstock, more preferably have an increase in average median particlediameter of 50 microns or more over the average median particle diameterof the feed stock, and more preferably have an increase in averagemedian particle diameter of 100 microns or more over the average medianparticle diameter of the feed stock.

Further, the resulting aggregate or proppant may have a decrease inaverage median particle diameter of 1 micron or more over the averagemedian particle diameter of the feed stock, more preferably have adecrease in average median particle diameter of 5 microns or more overthe average median particle diameter of the feed stock, more preferablyhave a decrease in average median particle diameter of 10 microns ormore over the average median particle diameter of the feed stock, morepreferably have a decrease in average median particle diameter of 20microns or more over the average median particle diameter of the feedstock, more preferably have a decrease in average median particlediameter of 50 microns or more over the average median particle diameterof the feed stock, and more preferably have a decrease in average medianparticle diameter of 100 microns or more over the average medianparticle diameter of the feed stock.

In addition, the system 100, 300 and/or separator assembly 120 may beoperated based upon one or more operating variables. For example, anoperating variable may include the type of particle fractions to becollected and/or generated (i.e. large/small, round/unround,spherical/non-spherical, etc.). As another example, an operatingvariable may include the yield of fractions following processing as apercent of processed fraction weight compared to total weight of feedstock (% wt/wt). The yield of fractions may be between 0.01% to 99.9% byweight of processed feed stock over weight of the feed stock, and morepreferably a yield of fractions of between 1.0% to 95% by weight ofprocessed feed stock over weight of the feed stock. As another example,an operating variable may include the number of stages provided in theprocessing system. As another example, an operating variable may includethe number of separator assemblies 120 provided in the system 100. Asanother example, an operating variable may include the type of separatorassemblies 120 provided in the system 100. As another example, anoperating variable may include the number and/or type of processedand/or unprocessed fractions to be combined for the targeted aggregateor proppant. As another example, an operating variable may include theinput rate of feed stock, for example the rate of feed stock perseparator assembly 120, or the rate of feed stock per system 100, 300.As another example, an operating variable may include the footprint ofthe system 100, 300 and/or separator assembly 120. Operation may bebased or optimized based upon these and other variables.

It should be appreciated that the resulting aggregate or proppant fromone or more examples of embodiments of separator assembly 120, and/orprocessing assembly 100, 300 may be further processed to separatedesired particles provided therein. For example, one or more fractionsof processed aggregate or proppant may be further processed in analternative processing assembly 100, 300 and/or separator(s) 120 adaptedto further process particles based upon one or more properties,including, but not limited to, particle shape, particle size, particlesurface texture, particle specific gravity, particle rollability, and/orparticle interaction with the separator 120 or assembly 100, 300material. For example, the resulting aggregate or proppant may remove apercentage of particles having an average Krumbein and Sloss RoundnessValue equal to or below 0.90, and more specifically an average Krumbeinand Sloss Roundness Value equal to or below 0.85, and more specificallyan average Krumbein and Sloss Roundness Value equal to or below 0.80,and more specifically an average Krumbein and Sloss Roundness Valueequal to or below 0.75, and more specifically an average Krumbein andSloss Roundness Value equal to or below 0.70, and more specifically anaverage Krumbein and Sloss Roundness Value equal to or below 0.65, andmore specifically an average Krumbein and Sloss Roundness Value equal toor below 0.60, and more specifically an average Krumbein and SlossRoundness Value equal to or below 0.55, and more specifically an averageKrumbein and Sloss Roundness Value equal to or below 0.50. As anadditional example, the resulting aggregate or proppant may remove apercentage of particles having an average Krumbein and Sloss SphericityValue equal to or below 0.90, and more specifically an average Krumbeinand Sloss Sphericity Value equal to or below 0.85, and more specificallyan average Krumbein and Sloss Sphericity Value equal to or below 0.80,and more specifically an average Krumbein and Sloss Sphericity Valueequal to or below 0.75, and more specifically an average Krumbein andSloss Sphericity Value equal to or below 0.70, and more specifically anaverage Krumbein and Sloss Sphericity Value equal to or below 0.65, andmore specifically an average Krumbein and Sloss Sphericity Value equalto or below 0.60, and more specifically an average Krumbein and SlossSphericity Value equal to or below 0.55, and more specifically anaverage Krumbein and Sloss Sphericity Value equal to or below 0.50.

For example, angular, irregular or abrasive material, such as particleshaving an average Krumbein and Sloss Sphericity Value of less than orequal to 0.8, and more specifically less than or equal to 0.70, and morespecifically less than or equal to 0.60, and more specifically less thanor equal to 0.50, and more specifically less than or equal to 0.40, andmore specifically less than or equal to 0.30, and/or an average Krumbeinand Sloss Roundness Value of less than or equal to 0.8, and morespecifically less than or equal to 0.7, and more specifically less thanor equal to 0.6, and more specifically less than or equal to 0.5, andmore specifically less than or equal to 0.4, and more specifically lessthan or equal to 0.3 may be desired. A separator assembly 120 may beconfigured such that the more round and/or more spherical particles areradially ejected or accepted from the separator assembly 120 as a firstfraction, leaving the desired angular, irregular or abrasive particlesor material as a desired second fraction. The angular particles ormaterial may be later mixed with substantially round and/or sphericalparticles (i.e. particles having an average Krumbein and SlossSphericity Value of 0.6 or greater, and more specifically of 0.7 orgreater, and more specifically of 0.8 or greater, and more specificallyof 0.9 or greater, and/or particles having an average Krumbein and SlossRoundness Value of 0.6 or greater, and more specifically of 0.7 orgreater, and more specifically of 0.8 or greater, and more specificallyof 0.9 or greater. The resulting recombinant aggregate or proppant orprop-pack (group of two or more grains or particles of a aggregate orproppant that together can form a matrix) of substantially round and/orspherical particles and substantially angular particles may have certainadvantages as an aggregate or proppant used during hydraulic fracturingor sand control, including, but not limited to, the reduction offlow-back in a gravel pack or hydraulic fracture or fissure, maintainingthe fissure in a wider open state, promoting an increase in permeabilityor conductivity, and/or increasing well productivity. A nonlimitingexample of one or more recombinant particles is provided below.

The following Examples provide an illustration of one or more examplesof embodiments of a recombinant particle mixture. More specifically, thefollowing Examples provide an illustration of one or more fractions of afeed stock processed by processing assembly 100, 300 and/or separator120 and subsequently recombined in a targeted or desired manner toproduce a recombinant particle mixture. The following Examples areprovided for illustration and are not intended to limit the scope of theinvention. The feedstock used to produce each fraction combined to forma recombinant sand can be the same or different. For example, all of thefractions combined may be the same size, such as a 20/40 size. Asanother example, the fractions combined may be differently sized, suchas a first processed fraction derived from a 20/40 size and a secondprocessed fraction derived from a 30/50 size.

Example 10

A sample feed stock was processed through system 100, 300, and morespecifically separator 120. Two fractions were produced and collectedthrough processing. A first fraction or spherical and rounded fractionwas collected. The spherical and rounded fraction was collected fromprocessed feed stock fraction which exited the flights of separator 120radially past the distal end 123 during processing. A second fraction orabrasive fraction was also collected. The abrasive fraction wascollected from processed feed stock fraction which remained on theflights at the completion of the radial processing through separator120. The spherical and rounded fraction had an average K&S SphericityValue of 0.88 and an average K&S Roundness Value of 0.86. In addition,the spherical and rounded fraction had 95% of particles having asphericity and roundness ≧0.8. Further, the spherical and roundedfraction had 0% of particles having a roundness ≦0.7, and 0% ofparticles had a sphericity and roundness ≦0.6. The abrasive fraction hadan average K&S Sphericity Value of 0.76 and an average K&S RoundnessValue of 0.76. In addition, the abrasive fraction had 50% of particleshaving a sphericity and roundness ≧0.8. Further, the abrasive fractionhad 35% of particles having a roundness ≦0.7, and 10% of particles had aroundness ≦0.6.

The spherical and rounded fraction and abrasive fraction were mixedtogether to form a recombinant aggregate or proppant. The recombinantaggregate or proppant was mixed at various ratios by weight of sphericaland rounded fraction to abrasive fraction. Each of the recombinantmixtures had certain different properties. For example, a firstrecombinant aggregate or proppant was made from 90% spherical androunded fraction and 10% abrasive fraction, or a 90:10 ratio. The firstrecombinant aggregate had an average K&S Sphericity Value of 0.82 and anaverage K&S Roundness Value of 0.83. In addition, the first recombinantaggregate had 70% of particles having a sphericity and roundness ≧0.8.Further, the first recombinant aggregate had 10% of particles having aroundness ≦0.7, and 5% of particles had a roundness ≦0.6.

As another example, a second recombinant aggregate or proppant was madefrom 80% spherical and rounded fraction and 20% abrasive fraction, or a80:20 ratio. The second recombinant aggregate had an average K&SSphericity Value of 0.77 and an average K&S Roundness Value of 0.82. Inaddition, the second recombinant aggregate had 70% of particles having asphericity and roundness ≧0.8. Further, the second recombinant aggregatehad 10% of particles having a roundness ≦0.7, and 5% of particles had aroundness ≦0.6.

As another example, a third recombinant aggregate or proppant was madefrom 70% spherical and rounded fraction and 30% abrasive fraction, or a70:30 ratio. The third recombinant aggregate had an average K&SSphericity Value of 0.77 and an average K&S Roundness Value of 0.79. Inaddition, the third recombinant aggregate had 50% of particles having asphericity and roundness ≧0.8. Further, the third recombinant aggregatehad 25% of particles having a roundness ≦0.7, and 10% of particles had aroundness ≦0.6.

Example 11

A sample feed stock was screened to a 20/40 grade or size fraction. Thefeed stock has a particle size, as measured by a 20 pan having an 850micron sieve opening size, and a 30 pan having a 600 micron sieveopening size. The particle size distribution, as a percent of totalweight retained in each pan, was 0.7% for the 20 pan, 30.2% for the 30pan, and 69.1% for the >30 pan. Similarly, the feed stock was measuredby size using a U.S. Mesh Size of 20 to 30 (having a particle sizeinterval of between 850 to 600 microns), and 30 to 40 (having a particlesize interval of between 600 to 425 microns). The particle sizedistribution, as a percent of mass, was 30.2% for the 20 to 30 meshsize, and 69.1% for the 30 to 40 mesh size. The mean particle diameterfor the feed stock was 577 microns, and the median particle diameter(MPD) was 555 microns. The feed stock was then processed through system100, 300, and more specifically separator 120. The spirals of separator120 had a five inch radius. Splitter assembly 430 was provided alongflights 122. The splitter assembly 430 was provided one inch radiallyaway from central member 124. Two fractions were produced and collectedthrough processing. A first fraction or spherical and rounded fractionwas collected. The spherical and rounded fraction was collected fromprocessed feed stock fraction which exited the flights of separator 120radially past the distal end 123 during processing. A second fraction orangular fraction was also collected. The angular fraction was theresulting processed feed stock fraction between proximal end 121 orcentral member 124 and splitter assembly 430, and was acquired withinthe one inch radial distance.

The spherical and rounded fraction had a particle size distribution, asa percent of total weight retained in each pan, of 3.5% for the 20 pan,64.9% for the 30 pan, and 31.6% for the >30 pan. Similarly, thespherical and rounded fraction was measured by size using a U.S. MeshSize of 20 to 30 (having a particle size interval of between 850 to 600microns), and 30 to 40 (having a particle size interval of between 600to 425 microns). The particle size distribution, as a percent of mass,was 64.9% for the 20 to 30 mesh size, and 31.6% for the 30 to 40 meshsize. The mean particle diameter for the spherical and rounded fractionwas 655 microns, and the median particle diameter (MPD) was 675 microns.

The angular fraction had a particle size distribution, as a percent oftotal weight retained in each pan, of 2.7% for the 20 pan, 18.9% for the30 pan, and 78.4% for the >30 pan. Similarly, the angular fraction wasmeasured by size using a U.S. Mesh Size of 20 to 30 (having a particlesize interval of between 850 to 600 microns), and 30 to 40 (having aparticle size interval of between 600 to 425 microns). The particle sizedistribution, as a percent of mass, was 18.9% for the 20 to 30 meshsize, and 78.4% for the 30 to 40 mesh size. The mean particle diameterfor the angular fraction was 554 microns, and the median particlediameter (MPD) was 535 microns.

The spherical and rounded fraction and the angular fraction weresubsequently mixed together in a ratio of 80:20, or 80% spherical androunded fraction and 20% angular fraction as a percent by weight. Thecombined recombinant fraction had a particle size distribution, as apercent of total weight retained in each pan, of 1.5% for the 20 pan,54.5% for the 30 pan, and 43.9% for the >30 pan. Similarly, the combinedrecombinant fraction was measured by size using a U.S. Mesh Size of 20to 30 (having a particle size interval of between 850 to 600 microns),and 30 to 40 (having a particle size interval of between 600 to 425microns). The particle size distribution, as a percent of mass, was54.5% for the 20 to 30 mesh size, and 43.9% for the 30 to 40 mesh size.The mean particle diameter for the combined recombinant fraction was 630microns, and the median particle diameter (MPD) was 630 microns.

Example 12

A sample feed stock was screened to a 30/50 grade or size fraction. Thefeed stock has a particle size, as measured by a 30 pan having a 600micron sieve opening size, and a 40 pan having a 425 micron sieveopening size. The particle size distribution, as a percent of totalweight retained in each pan, was 3.7% for the 30 pan, 44.1% for the 40pan, and 52.2% for the >40 pan. Similarly, the feed stock was measuredby size using a U.S. Mesh Size of 30 to 40 (having a particle sizeinterval of between 600 to 425 microns), and 40 to 50 (having a particlesize interval of between 425 to 300 microns). The particle sizedistribution, as a percent of mass, was 44.1% for the 30 to 40 meshsize, and 52.2% for the 40 to 50 mesh size. The mean particle diameterfor the feed stock was 431 microns, and the median particle diameter(MPD) was 420 microns. The feed stock was then processed through system100, 300, and more specifically separator 120. The spirals of separator120 had a five inch radius. Two fractions were produced and collectedthrough processing. The first fraction or spherical and roundedfraction, was collected.

The spherical and rounded fraction of the 30/50 was collected fromprocessed feed stock fraction which exited the flights of separator 120radially past the distal end 123 during processing. The spherical androunded fraction of the 30/50 had a particle size distribution, as apercent of total weight retained in each pan, of 11.1% for the 30 pan,33.3% for the 40 pan, and 55.6% for the >40 pan. Similarly, thespherical and rounded fraction of the 30/50 was measured by size using aU.S. Mesh Size of 30 to 40 (having a particle size interval of between600 to 425 microns), and 40 to 50 (having a particle size interval ofbetween 425 to 300 microns). The particle size distribution, as apercent of mass, was 33.3% for the 30 to 40 mesh size, and 55.6% for the40 to 50 mesh size. The mean particle diameter for the spherical androunded fraction of the 30/50 was 419 microns, and the median particlediameter (MPD) was 415 microns.

The spherical and rounded fraction of the 20/40 grade (in Example 11)was then mixed together with the spherical and rounded fraction of the30/50 in a ratio of 90:10, or 90% spherical and rounded fraction of the20/40 grade and 10% spherical and rounded fraction of the 30/50 grade.The combined recombinant fraction had a particle size distribution, as apercent of total weight retained in each pan, of 3.2% for the 20 pan,60% for the 30 pan, and 32% for the 40 pan, and 5.6% for the 50 pan.Similarly, the combined recombinant fraction was measured by size usinga U.S. Mesh Size of 20 to 30 (having a particle size interval of between850 to 600 microns), 30 to 40 (having a particle size interval ofbetween 600 to 425 microns), and 40 to 50 (having a particle sizeinterval of between 425 to 300 microns). The particle size distribution,as a percent of mass, was 59.5% for the 20 to 30 mesh size, 31.8% forthe 30 to 40 mesh size, and 5.6% for the 40 to 50 mesh size. The meanparticle diameter for the combined recombinant fraction was 635 microns,and the median particle diameter (MPD) was 650 microns.

The invention disclosed herein provides certain advantages. For example,the processing assembly, system, and associated separator processes feedstock to produce a substantially round and substantially sphericalproppant suitable for hydraulic fracturing or sand control, such as forgravel packing, from common sources. This resulting proppantadvantageously increases hydrocarbon productivity from a fissure orfracture network due to the high degree of proppant sphericity androundness and/or increased or decreased mean or median particlediameter, or particle size distribution, or modified MPD (i.e. anincrease in MPD or a decrease in MPD), or modified surface texture. Thismay reduce pressure loss in the fissure or fracture network leading toan increase in conductivity and well productivity. In addition, atailored size distribution profile or modified mean particle diameter orMPD (such as a coarser MPD within a sand size grade to increaseconductivity; or a finer MPD within a sand size grade to increasestrength) can improve a performance of a proppant and can increasehydrocarbon productivity. In addition, the resulting proppant canadvantageously reduce embedment of the proppant within a wall of afissure or fracture in the fissure network. This reduction can maintainthe fissure or fracture in a wider open state, also increasingconductivity and productivity of the well. Further, the resultingproppant advantageously can promote improved properties of a proppant,including increased crush resistance, strength, permeability,conductivity, and reduced tortuosity, turbulization or pressure lossesand maintain a more even stress distribution throughout the prop-pack.In addition, the processing assembly, system, and associated separatorprovided herein has several advantages, including the ability to processa feed stock which is generally unsuitable for use as a proppant andmore specifically as a proppant suitable for use in hydraulicfracturing, and produce a proppant which is suitable for use inhydraulic fracturing and/or sand control. The processing assembly,system, and associated separator may be mobile and/or operated “on thefly.” These and other advantages are realized by the invention andassociated disclosure provided herein.

Although various representative examples of embodiments of thisinvention have been described above with a certain degree ofparticularity, those skilled in the art could make numerous alterationsto the disclosed embodiments without departing from the spirit or scopeof the inventive subject matter set forth in the specification andclaims. Joinder references (e.g., attached, coupled, connected) are tobe construed broadly and may include intermediate members between aconnection of elements and relative movement between elements. As such,joinder references do not necessarily infer that two elements aredirectly connected and in fixed relation to each other. In someinstances, in methodologies directly or indirectly set forth herein,various steps and operations are described in one possible order ofoperation, but those skilled in the art will recognize that steps andoperations may be rearranged, replaced, or eliminated withoutnecessarily departing from the spirit and scope of the presentinvention. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative only and not limiting. Changes in detail or structuremay be made without departing from the spirit of the invention asdefined in the appended claims.

Although the present invention has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

What is claimed is:
 1. A proppant resulting from a separator meanscomprising a plurality of particles, the particles have an averageKrumbein and Sloss Sphericity Value of 0.6 or above, and an averageKrumbein and Sloss Roundness Value of 0.6 or above.
 2. The proppant ofclaim 1, wherein the particles have an average Krumbein and SlossSphericity Value of 0.8 or above, and an average Krumbein and SlossRoundness Value of 0.8 or above.
 3. The proppant of claim 1, wherein theparticles have an average Krumbein and Sloss Sphericity Value of between0.8 and 0.9, and an average Krumbein and Sloss Roundness Value ofbetween 0.8 and 0.9.
 4. The proppant of claim 1, wherein the particleshave an average Krumbein and Sloss Sphericity Value of at least 0.9, andan average Krumbein and Sloss Roundness Value of at least 0.9.
 5. Theproppant of claim 1, wherein the particles include sand particles. 6.The proppant of claim 1, wherein the particles include silica sandparticles.
 7. The proppant of claim 1, wherein the proppant is greaterthan or equal to 0.1% by weight of a total weight of feed stock prior toprocessing by the separator means.
 8. The proppant of claim 1, whereinthe proppant is greater than or equal to 5% by weight of a total weightof feed stock prior to processing by the separator means.
 9. Theproppant of claim 1, wherein the proppant is greater than or equal to10% by weight of a total weight of feed stock prior to processing by theseparator means.
 10. The proppant of claim 1, wherein the proppant hasan average particle size of 100 to 4,000 microns.
 11. An aggregateresulting from a processing means which separates a feed stock, theaggregate comprises a plurality of particles, the particles have anaverage median particle diameter of at least 1 micron more than theaverage median particle diameter of the feed stock.
 12. The aggregate ofclaim 11, wherein the particles have an average median particle diameterof at least 10 microns more than the average median particle diameter ofthe feed stock.
 13. The aggregate of claim 11, wherein the particleshave an average median particle diameter of at least 20 microns morethan the average median particle diameter of the feed stock.
 14. Aproppant processing assembly comprising: a separator assembly having acentral member extending from a first end to a second end, the centralmember supporting at least one helical flight provided between the firstand second ends, the helical flight having a width provided between aproximal end and a distal end; an assembly housing provided around aportion of the separator assembly, the assembly housing includes acollection portion for receiving a first fraction of processed feedstock which exits the separator assembly radially away from the centralmember outward past the distal end, the collection portion includes afirst outlet; a second outlet coupled to the separator assembly forreceiving a second fraction of processed feed stock which exits theseparator assembly at the second end of the at least one helical flight;and a fraction acquisition assembly being selected from the groupconsisting of: a radial slot provided in a portion of the at least onehelical flight; a radial rim provided on the distal end of the at leasta portion of one helical flight; a splitter assembly provided along theradius of the at least one helical flight; and a collection assemblyformed by a first collection member coupled to the central member at afirst end, and a second collection member coupled to the firstcollection member at a second end, the second collection member beingperpendicular to the first collection member, and the first collectionmember being approximately parallel to the at least one helical flightand having a second width which is greater than the width of the atleast one helical flight.
 15. The proppant processing assembly of claim14, wherein a plurality of nested helical flights are provided on thecentral member.
 16. The proppant processing assembly of claim 14,wherein a portion of the central member is hollow, the hollow portionbeing coupled to the second outlet, and a termination member is providedat the second end of the at least one helical flight in order to directthe second fraction of processed feed stock from the at least onehelical flight, through the hollow portion, and to the second outlet.17. The proppant processing assembly of claim 14, further comprising afeed stock delivery assembly including a feed stock supply line adaptedto provide feed stock to the separator assembly.
 18. The proppantprocessing assembly of claim 14, wherein the first outlet is an outletfor a first fraction of processed material, and the second outlet is anoutlet for a second fraction of processed material.
 19. A recombinantaggregate comprising: a first aggregate fraction resulting from aprocessing assembly, the first aggregate having a first particle sizeprofile; a second aggregate fraction resulting from a processingassembly, the second aggregate having a second particle size profile;the first and second aggregate fractions are combined at a ratio suchthat the resulting mixture has a third particle size profile differentfrom the first particle size profile and second particle size profile.20. The recombinant aggregate of claim 19, wherein the third particlesize profile is different than a particle size profile of a feed stockprovided to the processing assembly for generating the first aggregatefraction or second aggregate fraction.